Process for preparing catalyst system

ABSTRACT

A polymer bound ligand represented by the formula QM(R) m  and process for preparing same are provided, wherein Q is a polystyrene, M is Si, C, Ge, Sn, P, or N, each R is a that at least one R is a cyclopentadienyl-type compound, and m is 2 or 3, said process comprising reacting a metallated polystyrene and an organohalide compound, wherein the polystyrene is metallated with an alkali metal, and wherein said organohalide compound is represented by the formula XM(R) m  wherein X is a halide. Other aspects of the present invention include a polymer bound metallocene represented by the formula QM(R) m  ZY n  and a process for preparing same, wherein Z is a transition metal, Y is a halide, methyl, hydrogen, or a cyclopentadienyl-type group, and n is 2 or 3. Other aspects of the present invention include a catalyst system comprising the polymer bound metallocene and an organoaluminoxane, a method for preparing same, and a polymerization process employing the catalyst system.

This is a divisional of copending application Ser. No. 08/268,425, filedJun. 30, 1994.

The present invention relates to polymer bound ligands, polymer boundmetallocenes, catalyst systems, processes for preparing same, and theuse of such catalyst systems in olefin polymerization.

BACKGROUND OF THE INVENTION

Metallocene catalysts have been used in homogenous solutionpolymerizations. Since such homogeneous catalysts are soluble in thepolymerization medium it is generally observed that the resultingpolymer has low bulk density.

Attempts to use soluble metallocene catalysts in a slurry or particleform type polymerization are currently not commercially feasible. It hasbeen observed that when such particle form polymerizations are carriedout in the presence of a soluble metallocene catalyst, large amounts ofpolymeric material are formed on the surfaces of the polymerizationvessel. This fouling produces an adverse effect on the heat transfer andalso results in the need for periodic, if not continuous, cleaning ofthe reactor.

It would therefore be desirable to produce economical solid metallocenecatalysts useful in polymerization processes free of reactor fouling.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a solid polymer boundligand useful in preparing heterogeneous metallocene catalysts.

Another object of the present invention is to provide an economicalprocess for preparing a solid polymer bound ligand useful in preparingmetallocene catalysts.

Another object of the present invention is to provide a solid polymerbound metallocene useful in olefin polymerization which does not producesignificant reactor fouling in a particle form polymerization process.

Another object of the present invention is to provide an efficient andeconomical process for preparing a polymer bound metallocene catalyst.

Still another object of the present invention is to provide apolymerization process free of significant reactor fouling, especiallyin a particle form process.

In accordance with the present invention, a polymer bound ligandrepresented by the formula QM(R)_(m) and a process for preparing sameare provided, wherein Q is a polystyrene, M is Si, C, Ge, Sn, P, or N,each R is a hydrocarbyl group individually selected, with the provisothat at least one R is a cyclopentadienyl-type group and when M is C atleast two R groups are cyclopentadienyl-type groups, as hereinafterdefined, and m is 2 or 3, said process comprising reacting a metallatedpolystyrene and an organohalide compound, wherein the polystyrene ismetallated with an alkali metal, and wherein said organohalide compoundis represented by the formula XM(R)_(m) wherein X is a halide. Otheraspects of the present invention include a polymer bound metallocenerepresented by the formula QM(R)_(m) ZY_(n), wherein Z is a transitionmetal, Y is a halide, methyl, hydrogen, or a cyclopentadienyl-typegroup, and n is 2 or 3, and a process for preparing same comprisingreacting the polymer bound ligand and an alkali metal compound toproduce a metallated polymer bound ligand and then reacting themetallated polymer bound ligand and a transition metal halide, ZY₄.Other aspects of the present invention include a catalyst systemcomprising the polymer bound metallocene and an organoaluminoxane, amethod for preparing same, and a polymerization process employing thecatalyst system.

DETAILED DESCRIPTION OF THE INVENTION

A polymer bound ligand represented by the formula QM(R)_(m), wherein Qis a polystyrene, M is Si, C, Ge, Sn, P, or N, each R is a hydrocarbylgroup individually selected, with the proviso that at least one R is acyclopentadienyl-type group and when M is C at least two R groups arecyclopentadienyl-type groups, and m is 2 or 3, is prepared by reacting ametallated polystyrene and an organohalide compound, wherein saidorganohalide compound is represented by the formula XM(R)_(m) wherein Xis a halide and M, R and m are as described above.

Cyclopentadienyl-type groups, as defined herein, are groups containing acyclopentadienyl-type group and include cyclopentadienyl, substitutedcyclopentadienyl, indenyl, substituted indenyl, fluorenyl, andsubstituted fluorenyl. The substituents include hydrocarbyl groupscontaining 1 to 12 carbon atoms, alkoxy groups containing 1 to 12 carbonatoms, or halide. Preferably the substituents are alkyl groupscontaining 1 to 10 carbon atoms, more preferably 1 to 6 carbon atoms.Some examples of substituents include methyl, ethyl, propyl, butyl,tert-butyl, isobutyl, amyl, isoamyl, hexyl, cyclohexyl, heptyl, octyl,nonyl, decyl, dodecyl, 2-ethylhexyl, pentenyl, butenyl, phenyl,chloride, bromide, and iodide.

The term polystyrene, as used herein, includes polystyrene, crosslinkedpolystyrene, polystyrene derivatives, such as methylated polystyrene,polystyrylcyclopentadiene, and (methylated polystyryl)cyclopentadiene,and functionalized polystyrene, such as halogenated polystyrene, whichare capable of being metallated with an alkali metal. Polystyrene iscommercially available and can be prepared by any method known in theart. A typical example for preparing polystyrene comprises reactingstyrene and divinylbenzene at polymerization conditions. Thepolymerization conditions can vary broadly. Generally the polymerizationtemperature is in the range of from about 20° C. to about 150° C.

Metallated polystyrene can be prepared by any method known in the art.One such method involves reacting polystyrene with an alkali metalcompound. Alkali metal compounds suitable for preparing metallatedpolystyrene are represented by the formula AR', wherein A is an alkalimetal selected from the group consisting of lithium, sodium, andpotassium and wherein R' is a hydrocarbyl group selected from the groupconsisting of alkyl, cycloalkyl, and aryl groups containing 1 to 12carbon atoms. Preferably R is an alkyl group containing 1 to 10 carbonatoms. Lithium alkyls containing 1 to 8 carbon atoms are especiallypreferred. Examples of preferred lithium alkyls include methyllithium,ethyllithium, propyllithium, butyllithium, pentyllithium andhexyllithium. Excellent results have been obtained with n-butyllithiumand it is especially preferred. The conditions for metallatingpolystyrene can vary broadly. Generally the temperature is in the rangeof from about 0° C. to about 100° C. When preparing the metallatedpolystyrene, the alkali metal compound is generally present in an amountin the range of from about 0.1 mole to about 50 moles alkali metalcompound per kilogram of polystyrene, preferably about 0.2 mole to about25 moles, and more preferably about 0.5 moles to about 20 moles.

Another effective method for preparing metallated polystyrene involvesreacting the alkali metal compound described above with halogenatedpolystyrene. A typical method of preparing halogenated polystyreneinvolves reacting polystyrene, Br₂, and FeCl₃ in chloroform, asdisclosed in J. Org. Chem. Vol. 41, No. 24, pages 3877-82 (1976), thedisclosure of which is incorporated herein by reference. The conditionsfor halogenating polystyrene by this method can vary broadly. Generallythe reaction temperature is in the range of from about 0° C. to about100° C. Generally the Br₂ is present in an amount in the range of fromabout 0.1 mole to about 50 moles Br₂ per kilogram polystyrene,preferably about 0.2 mole to about 25 moles, and more preferably about0.5 moles to about 20 moles. The halogenated polystyrene is then reactedwith the alkali metal compound. The alkali metal compound is generallypresent in an amount in the range of from about 0.1 mole to about 50moles alkali metal compound per kilogram of halogenated polystyrene,preferably about 0.2 mole to about 25 moles, and more preferably about0.5 moles to about 20 moles.

Another method for preparing metallated polystyrene involves reactingchloromethylated polystyrene, with a metallated cyclopentadienyl-typecompound. The chloromethylated polystyrene is prepared by reactingpolystyrene with chloromethyl alkyl ether to produce chloromethylatedpolystyrene, wherein the alkyl contains 1 to 6 carbon atoms, preferably1 to 3. The metallated cyclopentadienyl-type compound is an alkali metalsalt. The metallated cyclopentadienyl-type compound contains acyclopentadienyl-type group, and includes the groups cyclopentadienyl,substituted cyclopentadienyl, indenyl, and substituted indenyl, asdescribed above. Suitable metallated cyclopentadienyl-type compounds arecommercially available, examples include sodium cyclopentadiene orsodium indene. Metallated cyclopentadienyl-type compounds can beprepared by any method known in the art. Generally acyclopentadienyl-type compound is reacted with an alkali metal, such assodium, or an alkali metal compound, such as those described above formetallating polystyrene and disclosed in J. Am. Chem. Soc. 73, pages5135-5138. For example, alkyllithium and alkylsodium compoundscontaining 1 to 8 carbon atoms are especially effective. The reactionconditions for preparing the metallated cyclopentadienyl-type compoundcan vary broadly depending on the reactants employed. Generally thereaction temperatures for preparing the metallated cyclopentadienyl-typecompound are in the range of from about 0° C. to about 200° C. Themetallated cyclopentadienyl-type compound is then reacted with thechloromethylated polystyrene to produce a cyclopentadienyl-typepolystyrene, such as (methylated polystyryl)cyclpentadiene or(methylated polystyryl)indene. An alkali metal compound of the typedescribed above is then reacted with the cyclopentadienyl-typepolystyrene to produce a metallated polystyrene. A typical method isdisclosed in J. Am. Chem. Soc., 95, pages 2373-75 (1973) and J. Am.Chem. Soc., 97:8, pages 2128-32 (Apr. 16, 1975), the disclosures ofwhich are incorporated herein by reference. The amount of chloromethylalkyl ether relative to the amount of polystyrene is in the range offrom about 0.1 mole to about 50 moles per kilogram polystyrene,preferably about 0.2 mole to about 25 moles, and more preferably about0.5 moles to about 20 moles. The amount of metallatedcyclopentadienyl-type compound relative to the amount ofchloromethylated polystyrene is in the range of from about 0.1 mole toabout 50 moles per kilogram chloromethylated polystyrene, preferablyabout 0.2 mole to about 25 moles, and more preferably about 0.5 moles toabout 20 moles. The amount of alkali metal compound employed relative tothe polystyrene is in the range of from about 0.1 mole to about 50 molesper kilogram polystyrene, preferably about 0.2 mole to about 25 moles,and more preferably about 0.5 moles to about 20 moles. The reactionconditions of the various steps in preparing the metallated polystyrenewill generally include a temperature within the range of from about 0°C. to about 100° C.

The metallated polystyrene is then reacted with an organohalidecompound. The organohalide compound is represented by the formulaXM(R)_(m) wherein X is a halide, M is Si, C, Ge, Sn, P, or N, each R isa hydrocarbyl group independently selected from the group consisting ofalkyl, cycloalkyl, aryl, and cyclopentadienyl-type groups containing 1to 36 carbon atoms, preferably 1 to 24 atoms, with the proviso that atleast one R is a cyclopentadienyl-type group and when M is C at leasttwo R groups are cyclopentadienyl-type groups, and m is 2 or 3. Of theorganohalide compounds, chlorosilanes are preferred. Examples ofsuitable organohalide compounds include(chloro)(cyclopentadienyl)(diphenyl)silane,(chloro)(dicyclopentadienyl)(methyl)silane,(chloro)(cyclopentadienyl)(9-fluorenyl)(methyl)silane,(chloro)(difluorenyl)(methyl)silane,(chloro)(cyclopentadienyl)(methyl)(phenyl)silane,(chloro)(1-indenyl)(9-fluorenyl)(phenyl)silane,(chloro)(diphenyl)(9-fluorenyl)silane,(chloro)(9-fluorenyl)(methyl)(phenyl)silane,(chloro)(dimethyl)(1-indenyl)silane, (chloro)(diindenyl)(methyl)silane,(chloro)(cyclopentadienyl)(diphenyl)methane,(chloro)(dicyclpentadienyl)(methyl)methane,(chloro)(cyclopentadienyl)(9-fluorenyl)(methyl)methane,(chloro)(difluorenyl)(methyl)methane,(chloro)(cyclopentadienyl)(methyl)(phenyl)methane,(chloro)(1-indenyl)(9-fluorenyl)(phenyl)methane,(chloro)(diphenyl)(9-fluorenyl)methane,(chloro)(9-fluorenyl)(methyl)(phenyl)methane,(chloro)(dimethyl)(1-indenyl)methane, and(chloro)(diindenyl)(methyl)methane. Of the organohalide compounds,(chloro)(diphenyl)(9-fluorenyl)silane and(chloro)(cyclopentadienyl)(9-fluorenyl)(methyl)silane are preferred.

The organohalide compounds can be prepared by any method known in theart. One such method is disclosed in J. Am. Chem. Soc., 73, pages5135-5138, "Silylindenes and Silylindans", Sommer et al. the disclosureof which is incorporated herein by reference. The method involvesreacting organohalosilanes, such as dimethyldichlorosilane, withmetallated cyclopentadienyl-type compounds, such as 1-indenylsodium or1-indenyllithium. Typical examples of other suitable combinationsinclude reacting dichlorodiphenylsilane with fluorenyllithium, or(9-fluorenyl)(methyl)(dichloro)silane with cyclopentadienylsodium, ormethyltrichlorosilane with two equivalents fluorenyllithium. Metallatedcyclopentadienyl-type compounds can be prepared as described above. Thereaction conditions for preparing the organohalide compound can varybroadly depending on the reactants employed.

When reacting the organohalide compound and the metallated polystyrene,the organohalide compound is generally present in an amount in the rangeof from about 0.1 mole to about 50 moles organohalide compound perkilogram metallated polystyrene, preferably about 0.2 mole to about 25moles, and more preferably about 0.5 moles to about 20 moles. Themetallated polystyrene and the organohalide compound are reacted at atemperature in the range of from about 0° C. to about 100° C.

Examples of typical polymer bound ligands include(cyclopentadienyl)(diphenyl)(polystyryl)silane,(dicyclpentadienyl)(methyl)(polystyryl)silane,(cyclopentadienyl)(9-fluorenyl)(methyl)(polystyryl)silane,(cyclopentadienyl)(9-fluorenyl)(methyl)((polystyryl)methyl)silane,(difluorenyl)(methyl)(polystyryl)silane,(cyclopentadienyl)(methyl)(phenyl)(polystyryl)silane,(1-indenyl)(9-fluorenyl)(phenyl)(polystyryl)silane,(diphenyl)(9-fluorenyl)(polystyryl)silane,(diphenyl)(9-fluorenyl)((polystyryl)methyl)silane,(diphenyl)(9-fluorenyl)((polystyryl)cyclopentadienyl)silane,(9-fluorenyl)(methyl)(phenyl)(polystyryl)silane,(dimethyl)(1-indenyl)(polystyryl)silane,(1-indenyl)(methyl)(phenyl)(polystyryl)silane,(methyl)(diindenyl)(polystyryl)silane,(cyclopentadienyl)(diphenyl)(polystyryl)methane,(dicyclpentadienyl)(methyl)(polystyryl)methane,(cyclopentadienyl)(9-fluorenyl)(methyl)(polystyryl)methane,(cyclopentadienyl)(9-fluorenyl)(methyl)((polystyryl)methyl)methane,(difluorenyl)(methyl)(polystyryl)methane,(cyclopentadienyl)(methyl)(phenyl)(polystyryl)methane,(1-indenyl)(9-fluorenyl)(phenyl)(polystyryl)methane,(diphenyl)(9-fluorenyl)(polystyryl)methane,(diphenyl)(9-fluorenyl)((polystyryl)cyclopentadienyl)methane,(9-fluorenyl)(methyl)(phenyl)(polystyryl)methane,(dimethyl)(1-indenyl)(polystyryl)methane,(methyl)(1-indenyl)(polystyryl)methane, and(diindenyl)(methyl)(phenyl)(polystyryl)methane. Of the polymer boundligands, (diphenyl)(9-fluorenyl)((polystyryl)cyclopentadienyl)silane,(cyclopentadienyl)(9-fluorenyl)(methyl)(polystyryl)silane, and(diphenyl)(9-fluorenyl)(polystyryl)silane are preferred.

A polymer bound metallocene represented by the formula QM(R)_(m) ZY_(n)can be prepared by reacting a metallated polymer bound ligand with ametal halide, wherein Z is a transition metal and is Zr, Hf, Ti, or V,and wherein each Y is individually selected from the group consisting ofhalides, methyl, hydrogen, and cyclopentadienyl-type groups containing 5to 36 carbon atoms, with the proviso that at least three Y groups areselected from halides. Cyclopentadienyl-type groups include thosedescribed above for the organohalide compound. The metallated polymerbound ligand can be prepared by reacting the polymer bound ligand and analkali metal compound. Suitable conditions and alkali metal compoundsfor preparing the metallated polymer bound ligand are those describedabove for preparing the metallated polystyrene and include a temperaturein the range of from about 0° C. to about 100° C.

The metal halide is represented by the formula ZY₄, wherein Z and Y areas described above. Suitable metal halides include TiCl₄, ZrCl₄, HfCl₄,VCl₄, TiBr₄, ZrBr₄, HfBr₄, VBr₄, TiI₄, ZrI₄, HfI₄, VI₄,cyclopentadienylzirconium trichloride, cyclopentadienyltitaniumtrichloride, cyclopentadienylhafnium trichloride,cyclopentadienylvanadium trichloride,pentamethylcyclopentadienylzirconium trichloride,pentamethylcyclopentadienyltitanium trichloride,pentaamethylcyclopentadienylhafnium trichloride,pentamethylcyclopentadienylvanadium trichloride, indenylzirconiumtrichloride, and indenyltitanium trichloride. Zirconium-containing andtitanium-containing metal halides are preferred. Zirconium-containingmetal halides are more preferred and zirconium tetrachloride andcyclopentadienylzirconium trichloride are especially preferred.

The metal halide is generally present in an amount in the range of fromabout 0.1 mole to about 50 moles metal halide per kilogram polymer boundligand, preferably about 0.2 mole to about 25 moles, and more preferablyabout 0.5 moles to about 20 moles. The metallated polymer bound ligandand the metal halide are generally reacted at a temperature in the rangeof from about 0° C. to about 100° C.

Examples of typical polymer bound metallocenes include(diphenyl)(9-fluorenyl)((polystyryl)cyclopentadienyl)silane zirconiumdichloride, (diphenyl)(9-fluorenyl)((polystyryl)methyl)silanecyclopentadienylzirconium dichloride,(diphenyl)(9-fluorenyl)(polystyryl)silane cyclopentadienylzirconiumdichloride, (cyclopentadienyl)(diphenyl)(polystyryl)silanecyclopentadienylzirconium dichloride,(dicyclpentadienyl)(methyl)(polystyryl)silane zirconium dichloride,(cyclopentadienyl)(9-fluorenyl)(methyl)(polystyryl)silane zirconiumdichloride,(cyclopentadienyl)(9-fluorenyl)(methyl)((polystyryl)methyl)silanezirconium dichloride, (difluorenyl)(methyl)(polystyryl)silane zirconiumdichloride, (cyclopentadienyl)(methyl)(phenyl)(polystyryl)silaneindenylzirconium dichloride,(1-indenyl)(9-fluorenyl)(phenyl)(polystyryl)silane zirconium dichloride,(9-fluorenyl)(methyl)(phenyl)(polystyryl)silanecyclopentadienylzirconium dichloride,(dimethyl)(1-indenyl)(polystyryl)silane indenylzirconium dichloride,(1-indenyl)(methyl)(polystyryl)silane cyclopentadienylzirconiumdichloride, (diindenyl)(methyl)(polystyryl)silane zirconium dichloride,(diphenyl)(9-fluorenyl)(polystyrylcyclopentadienyl)methane zirconiumdichloride, (cyclopentadienyl)(diphenyl)(polystyryl)methanecyclopentadienylzirconium dichloride,(dicyclpentadienyl)(methyl)(polystyryl)methane zirconium dichloride,(cyclopentadienyl)(9-fluorenyl)(methyl)(polystyryl)methane zirconiumdichloride, (difluorenyl)(methyl)(polystyryl)methane zirconiumdichloride, (cyclopentadienyl)(methyl)(phenyl)(polystyryl)methanecyclopentadienylzirconium dichloride,(1-indenyl)(9-fluorenyl)(phenyl)(polystyryl)methane zirconiumdichloride, dichloride, (9-fluorenyl)(methyl)(phenyl)(polystyryl)methanecyclopentadienylzirconium dichloride,(dimethyl)(1-indenyl)(polystyryl)methane cyclopentadienylzirconiumdichloride, (1-indenyl)(methyl)(polystyryl)methanecyclopentadienylzirconium dichloride, and(diindenyl)(methyl)(polystyryl)methane zirconium dichloride. Of these,(diphenyl)(9-fluorenyl)((polystyryl)cyclopentadienyl)silane zirconiumdichloride, (cyclopentadienyl)(9-fluorenyl)(methyl)(polystyryl)silanezirconium dichloride, and (diphenyl)(9-fluorenyl)(polystyryl)silanecyclopentadienylzirconium dichloride are preferred.

The polymer bound metallocenes can be used in combination with asuitable cocatalyst to produce catalyst systems for the polymerizationof olefins. Examples of suitable cocatalysts include any of thoseorganometallic cocatalysts which have in the past been employed inconjunction with transition metal-containing olefin polymerizationcatalysts. Some typical examples include organometallic compounds ofmetals of Groups IA, IIA, and IIIB of the Periodic Table. Examples ofsuch compounds include organometallic halide compounds, organometallichydrides, and metal hydrides. Some specific examples includetriethylaluminum, tri-isobutylaluminum, diethylaluminum chloride,diethylaluminum hydride, and the like. Other examples of knowncocatalysts include the use of a stable non-coordinating counter anionsuch as disclosed in U.S. Pat. No. 5,155,080, e.g. using triphenylcarbenium tetrakis(petafluorophenyl)boronate. Another example would bethe use of a mixture of trimethylaluminum and dimethylfluoroaluminumsuch as disclosed by Zambelli et, Macromolecules, 22, 2186 (1989).

Currently, organoaluminoxane cocatalysts are the preferred cocatalysts.Various techniques are known for making organoaluminoxanes. Onetechnique involves the controlled addition of water to atrialkylaluminum. Another technique involves combining atrialkylaluminum and a hydrocarbon with a compound containing water ofadsorption or a salt containing water of crystallization. Many suitableorganoaluminoxanes are commercially available.

Typically the organoaluminoxanes comprise oligomeric, linear and/orcyclic hydrocarbyl aluminoxanes having repeating units of the formula##STR1## wherein each R¹ is a hydrocarbyl group, preferably an alkylgroup containing 1-8 carbon atoms, x is 2 to 50, preferably 4 to 40, andmore preferably 10 to 40. Typically R¹ is predominantly methyl or ethyl.Preferably at least about 30 mole percent of the repeating groups havean R¹ which is methyl, more preferably at least 50 mole percent, andstill more preferably at least 70 mole percent. Generally in thepreparation of an organoaluminoxane, a mixture of linear and cycliccompounds is obtained. Organoaluminoxanes are commercially available inthe form of hydrocarbon solutions, generally aromatic hydrocarbonsolutions.

A solid organoaluminoxy product can be prepared by reacting anorganoaluminoxane and an oxygen-containing compound selected from thegroup consisting of organo boroxines, organic boranes, organicperoxides, alkylene oxides, and organic carbonates. Organo boroxines arepreferred.

The amount of organoaluminoxane relative to the polymer boundmetallocene can vary broadly depending upon the particular catalystselected and the results desired. Typically, the organoaluminoxane ispresent in the amount of about 0.5 moles to about 10,000 moles aluminumper mole of metal in the polymer bound metallocene, preferably about 10moles to about 5,000 moles, and more preferably 50 moles to 5,000 moles.

The above described steps for preparing the polymer bound ligand, thepolymer bound metallocene, and the catalyst system are generallyconducted in the presence of a solvent or a diluent. Typical solvents ordiluents include for example tetrahydrofuran, dichloromethane, toluene,heptane, hexane, cyclohexane, toluene, benzene, and diethylether.Preferably the polymer bound ligand and the polymer bound metalloceneare prepared employing a noncoordinating solvent such as a noncyclicether.

A variety of olefin compounds are suitable for use as monomers in thepolymerization process of the present invention. Olefins which can beemployed include linear, branched, and cyclic aliphatic olefins. Whilethe invention would appear to be suitable for use with any aliphaticolefin known to be employed with metallocenes, those olefins having 2 to18 carbon atoms are most often used. Ethylene and propylene areespecially preferred. Often a second olefin (comonomer) having from 2 to12 carbon atoms, preferably from 4 to 10 carbon atoms can be employed.Typical monomers include propylene, 1-butene, 1-pentene,4-methyl-1-pentene, 2-pentene, 1-hexene, 2-hexene, cyclohexene,1-heptene, and dienes such as butadiene.

The polymerization processes according to the present invention can beperformed either batchwise or continuously. The olefin, polymer boundmetallocene, and organoaluminoxane cocatalyst can be contacted in anyorder. It is preferred that the polymer bound metallocene and theorganoaluminoxane are contacted prior to contacting with the olefin.Generally a diluent such as isobutane is added to the reactor. Thereactor is heated to the desired reaction temperature and olefin, suchas ethylene, is then admitted and maintained at a partial pressurewithin a range of from about 0.5 MPa to about 5.0 MPa (70-725 psi) forbest results. At the end of the designated reaction period, thepolymerization reaction is terminated and the unreacted olefin anddiluent vented. The reactor can be opened and the polymer can becollected as a free-flowing white solid and dried to obtain the product.

The reaction conditions for contacting the olefin and the catalystsystem can vary broadly depending on the olefin employed, and are thosesufficient to polymerize the olefins. Generally the temperature is inthe range of about 20° C. to about 300° C., preferably in the range of50° C. to 110° C. The pressure is generally in the range of from about0.5 MPa to about 5.0 MPa (70-725 psi).

The present invention is particularly useful in a gas phase particleform or slurry type polymerization. A particularly preferred typeparticle form polymerization involves a continuous loop reactor which iscontinuously charged with suitable quantities of diluent, catalystsystem, and polymerizable compounds in any desirable order. Typicallythe polymerization will include a higher alpha-olefin comonomer andoptionally hydrogen. Generally the particle form polymerization isconducted at a temperature in the range of about 50° C. to about 110°C., although higher and lower temperatures can be used. Polyethylenes ofvarying molecular weight distribution can be produced by varying theamount of hydrogen. The reaction product can be continuously withdrawnand the polymer recovered as appropriate, generally by flashing thediluent and unreacted monomers and drying the resulting polymer.

The following examples serve to show the present invention in detail byway of illustration and not by way of limitation.

EXAMPLES Example 1

Polystyrene was prepared in the following manner. A 2-L 3-neckround-bottom flask equipped with stirrer, gas inlet, and thermometer wascharged with a solution of 5.00 g poly(vinyl alcohol) in 1 L water andthen 200 ml (1.74 moles) styrene was added. Then 73.6 mL (0.435 mole)divinylbenzene (70% in ethylvinylbenzene)and 1.00g (6.01 mmol) ofazobisbutyronitrile were mixed and added to the flask. The stirrer speedwas regulated to adjust the drop size of the monomer. The temperaturewas increased to 60° C. Particles were seen after about 1 hour and thestirrer speed was doubled to prevent coagulation of the particles. Thetemperature was increased to 90° C. over a period of 5 hours and thereaction was maintained at this temperature for 1 hour. The reactionmixture was cooled and filtered and the polymer was washed 10 times with2 L water, 500 mL tetrahydrofuran (THF) and 500 mL acetone. The thusproduced polystyrene polymer was dried overnight at 80° C. and thenseparated with sieves into fractions of uniform grain size.

Chloromethylated polystyrene was prepared by reacting 60.00 gpolystyrene with 200 mL chloromethyl methyl ether for 1/2 hour at roomtemperature in a well ventilated fume hood. The mixture was cooled to 0°C. and 12 mL SnCl₄ in 50.0 mL chloromethyl methyl ether were addeddropwise over a period of 1/2 hour. The reaction mixture was stirred for72 hours at room temperature and then filtered. The yellow reactionproduct was washed with 500 mL dioxane/water (1:1), 500 mLdioxane/water/conc. HCl (2:2:1) and 500 mL dioxane. The thus producedchloromethylated polystyrene polymer was dried 48 hours at roomtemperature.

Methylpolystyrylcyclopentadiene was prepared by reacting 20.00 gchloromethylated polystyrene (24.0 mmol Cl) and 4.15 g (47.11 mmol) ofcyclopentadienylsodium in 100 mL THF. The reaction mixture was stirredfor 120 hours at room temperature. The yellow reaction product waswashed 5 times with 50 mL ethanol and 5 times with 50 mL THF. The thusproduced methylpolystyrylcyclopentadiene polymer was dried overnight atroom temperature.

Lithiated methylpolystyrylcyclopentadiene was prepared by reacting 5.90g methylpolystyrylcyclopentadiene with 20.0 mL (32.00 mmol)n-butyllithium in 50 mL diethyl ether. The reaction mixture was stirredfor 48 hours at room temperature. The supernatant was decanted and thethus produced orange lithiated methylpolystyrylcyclopentadienyl waswashed 3 times with 50 mL of diethyl ether.

The organohalide compound (chloro)(diphenyl)(9-fluorenyl)silane wasprepared by reacting fluorenyllithium with (dichloro)(diphenyl)silane.The fluorenyllithium was prepared by slowly reacting over ice 25.00 g(150.40 mmol) fluorene with 94.0 mL (150.40) n-butyllithium (1.6M inhexane) in 150 mL diethyl ether. The dark red reaction solution wasstirred overnight at room temperature. The solvent was evaporated in avacuum. The thus produced yellow, solid fluorenyllithium was added to asolution of 45.0 mL (216.82 mmol) (dichloro)(diphenyl)silane in 500 mLpentane. The reaction mixture was stirred overnight at room temperature.The solvent was evaporated in a vacuum, the yellow residue was extractedwith diethyl ether and filtered through sodium sulfate. The solvent wasevaporated in a vacuum and the viscous residue was mixed with 100 mLpentane. The thus produced organohalide compound(chloro)(diphenyl)(9-fluorenyl)silane precipitated as a white solid witha yield of 80-90%.

The polymer bound ligand(diphenyl)(9-fluorenyl)((polystyryl)methyl)cyclopentadienyl)silane wasprepared by reacting (chloro)(diphenyl)(9-fluorenyl)silane withlithiated methylpolystyrylcyclopentadiene prepared as described above.The lithiated methylpolystyrylcyclopentadienyl was reacted with 5 mLN,N,N',N'-tetramethylethylenediamine and 2.68 g (7.00 mmol)(chloro)(diphenyl)(9-fluorenyl)silane in 50 mL diethyl ether. Thereaction mixture was stirred 48 hours at room temperature. Thesupernatant was decanted and the thus produced yellowish polymer boundligand(diphenyl)(9-fluorenyl)((polystyryl)methyl)cyclopentadienyl)silane waswashed 5 times with 50 mL diethyl ether.

The polymer bound metallocene(diphenyl)(9-fluorenyl)((polystyryl)methyl)cyclopentadienyl)silanezirconium dichloride was prepared by reacting lithiated polymer boundligand with zirconium tetrachloride. The lithiated polymer bound ligandwas prepared by reacting(diphenyl)(9-fluorenyl)((polystyryl)methyl)cyclopentadienyl)silaneprepared as described above and 20.0 mL (32.00 mmol) n-butyllithium in50 mL diethyl ether. The reaction mixture was stirred for 48 hours atroom temperature. The supernatant was decanted and the orange polymerwas washed 3 times with 50 mL diethyl ether. The thus lithiated polymerbound ligand was reacted with 1.65 g (7.08 mmol) zirconium tetrachloridein 50 mL diethyl ether. The reaction mixture was stirred overnight atroom temperature. The supernatant was decanted and the yellow polymerwas washed 3 times with 50 mL diethyl ether. The thus produced polymerbound metallocene(diphenyl)(9-fluorenyl)((polystyryl)methyl)cyclopentadienyl)silanezirconium dichloride was dried overnight at room temperature.

Example 2

Lithiated polystyrene was prepared by reacting brominated polystyreneand n-butyllithium. Brominated polystyrene was prepared by reacting50.00 g polystyrene (0.4 mol phenyl groups) prepared as described above,6.0 mL Br₂ (0.1 mol) and 1.0 g FeCl₃ in 500 mL chloroform. The red-brownsuspension was stirred for 48 hours at room temperature. The polymer wasfiltered and washed 2 times with 100 mL THF, 6 times with 100 mLtoluene, 2 times with 100 mL acetone, 1 time with 100 mL hexane and 1time with 100 mL ether. The thus produced yellow brominated polystyrenepolymer was dried overnight at 60° C. The brominated polystyrene wasthen lithiated by reacting 5.60 g brominated polystyrene (16.8 mmol Br)with 20.0 mL (32.0 mmol) n-butyllithium (1.6M in hexane) in 60 mLtoluene. The mixture was stirred for 5 hours at 60° C. The yellowpolymer turned brown during the process. The supernatant was decantedand the thus produced lithiated polystyrene was washed 5 times with 50mL diethyl ether.

The organohalide compound(chloro)(cyclopentadienyl)(9-fluorenyl)(methyl)silane was prepard byreacting (9-fluorenyl)(methyl)(dichloro)silane and cyclopentadienylsodium. The (9-fluorenyl)(methyl)(dichloro)silane was prepared byreacting fluorenyllithium and (methyl)(trichloro)silane. Thefluorenyllithium was prepared by reacting 20 g (120 mmol) of fluoreneand 76 mL butyllithium (1.6M in hexane) in 200 mL ether. The mixture wasstirred for one hour at room temperature and then the solvent wasremoved. The thus prepared solid fluorenyllithium was added in portionsto a solution of 36 g (40 mL, 241 mmol) of (methyl)(trichloro)silane in700 mL pentane. The mixture was stirred for one hour at room temperatureand the reaction mixture was then filtered over sodium sulfate. Thesolution was concentrated by evaporation to 30% of its volume andcrystallized at -30° C. The thus produced (9-fluorenyl)(methyl)(dichloro)silane was in the form of a whitecrystalline powder with a yield of 95%. Then 5 g (17.9 mmol)(9-fluorenyl)(methyl)(dichloro)silane was reacted with 1.6 g (18 mmol)cyclopentadienyl sodium. The mixture was stirred for 4 hours at roomtemperature. The mixture was filtered over sodium sulfate and thesolvent removed. The thus produced(chloro)(cyclopentadienyl)(9-fluorenyl)(methyl)silane was a brightyellow solid.

The polymer bound ligand(cyclopentadienyl)(9-fluorenyl)(methyl)(polystyryl)silane was preparedby reacting (chloro)(cyclopentadienyl)(9-fluorenyl)(methyl)silane withlithiated polystyrene. The lithiated polystyrene prepared above wasreacted with 6.04 g (15.64 mmol)(chloro)(cyclopentadienyl)(9-fluorenyl)(methyl)silane in 50 mL diethylether. The reaction mixture was stirred for 48 hours at roomtemperature. The supernatant was decanted and the thus produced yellowpolymer bound ligand(cyclopentadienyl)(9-fluorenyl)(methyl)(polystyryl)silane was washed 5times with 50 mL diethyl ether.

The polymer bound metallocene(cyclopentadienyl)(9-fluorenyl)(methyl)(polystyryl)silane zirconiumdichloride was prepared by reacting lithiated polymer bound ligand withzirconium tetrachloride. The lithiated polymer bound ligand was preparedby reacting (cyclopentadienyl)(9-fluorenyl)(methyl)(polystyryl)silaneproduced as described above with 20 mL (32.00 mmol) n-butyllithium in 50mL diethyl ether. The reaction mixture was stirred for 48 hours at roomtemperature. The supernatant was decanted and the orange polymer waswashed 3 times with 50 mL diethyl ether. The thus produced lithiatedpolymer bound ligand was then reacted with 3.70 g (15.87 mmol zirconiumtetrachloride in 50 mL diethyl ether. The reaction mixture was stirredovernight at room temperature. The supernatant was decanted and the thusproduced orange polymer bound metallocene(cyclopentadienyl)(9-fluorenyl)(methyl)(polystyryl)silane zirconiumdichloride was washed 3 times with 50 mL diethyl ether and driedovernight.

Catalyst systems were prepared by activating the polymer boundmetallocenes with excess methylaluminoxane (MAO). Ethylenepolymerizations were conducted in the following manner employing thecatalyst systems. A one liter autoclave was charged with 500 mL hexaneand a mixture of 10 mL MAO and a predetermined amount of polymer boundcatalyst. The autoclave temperature was raised to 60° C. and held forone hour at a constant ethylene pressure of 9 bar. The polymer boundcatalyst systems did not precipitate polymer on the wall of the reactorduring polymerization.

Example 3

Lithiated polystyrene was prepared by reacting 1 g brominatedpolystyrene, prepared as described above, with 10 mL n-butyllithium(1.6M in hexane) in 30 mL toluene in a flask under argon. The mixturewas stirred for 6 hours at 60° C. The reaction mixture was washed 3times with 50 mL ether.

The polymer bound ligand (diphenyl)(9-fluorenyl)(polystyryl)silane wasprepared by reacting the lithiated polystyrene was reacted with 1.53 g(chloro)(diphenyl)(9-fluorenyl)silane (4 mmol), prepared as described inExample 1, in 50 mL ether. The mixture was stirred at room temperaturefor 14 hours. The reaction mixture became yellow green. The solvent wasdecanted and washed 2 times with 50 mL ether, 50 mL methanol, and 2times with 50 mL ether.

Polymer bound metallocene (diphenyl)(9-fluorenyl)(polystyryl)silanecyclopentadienyl zirconium dichloride was prepared by reacting lithiatedpolymer bound ligand with cyclopentadienylzirconium trichloride. Thelithiated polymer bound ligand was prepared by reacting(diphenyl)(9-fluorenyl)(polystyryl)silane, prepared as described above,with 10 mL n-butyllithium (1.6M in hexane) in 50 mL ether. The mixturewas stirred for 24 hours at room temperature. The solvent was decantedand the yellow solid remaining was washed 3 times with 50 mL ether. Then50 mL ether and 0.79 g (3 mmol) cyclopentadienylzirconium trichloridewas added to the yellow solid and the mixture was stirred for 48 hours.The solvent was decanted and the thus produced(diphenyl)(9-fluorenyl)(polystyryl)silane cyclopentadienylzirconiumdichloride was washed 3 times with 50 mL ether and dried.

The olefin polymerization catalyst system was prepared by reacting 100mg (diphenyl)(9-fluorenyl)(polystyryl)silane cyclopentadienylzirconiumdichloride, prepared as described above, with 5 mL MAO (30 weight % intoluene). The polymerization reactor was charged with 500 mL hexane, 20mL MAO, and ethylene. The catalyst system was added to the reactor andthe temperature raised to 60° C. The polymerization was conducted for 1hour. The yield was 27 g polyethylene.

That which is claimed is:
 1. A process for preparing a catalyst systemcomprising reacting a polymer bound metallocene with an aluminoxanecocatalyst to form a catalyst system:wherein said polymer boundmetallocene is prepared by a process comprising reacting a polymer boundligand and an alkali metal compound containing 1 to 12 carbon atoms toform a metallated polymer bound ligand, and then reacting saidmetallated polymer bound ligand and a metal halide to form said polymerbound metallocene; wherein said polymer bound ligand is prepared by aprocess comprising reacting a metallated polystyrene and an organohalidecompound; wherein said polystyrene is metallated with an alkali metal;wherein said organohalide compound is represented by the formulaXM(R)_(m) wherein X is a halide, M is Si, C, Ge, Sn, P, or N, whereineach R is a hydrocarbyl group independently selected from the groupconsisting of alkyl, cycloalkyl, aryl, and cyclopentadienyl-type groupscontaining 1 to 36 carbon atoms, with the proviso that at least one Rgroup is a cyclopentadienyl-type group, wherein saidcyclopentadienyl-type groups are cyclopentadienyl, substitutedcyclopentadienyl, indenyl, substituted indenyl, fluorenyl, orsubstituted fluorenyl, wherein the substituents include hydrocarbylgroups containing 1 to 12 carbon atoms, alkoxy groups containing 1 to 12carbon atoms, or halide, and wherein m is 2or 3; wherein said metalhalide is represented by the formula ZY₄ ; wherein Z is Zr, Hf, Ti, orV; and wherein each Y is individually selected from the group consistingof halides, methyl and cyclopentadienyl-type groups containing 5 to 36carbon atoms, with the proviso that at least three Y groups are selectedfrom halides; and wherein said aluminoxane contains repeating units ofthe formula ##STR2## wherein each R¹ is a hydrocarbyl group containing1-8 carbon atoms and x is 2 to
 50. 2. A process according to claim 1where said aluminoxane cocatalyst is methylaluminoxane.
 3. A processaccording to claim 1 where said aluminoxane cocatalyst is present in anamount in the range of from about 0.5 moles to about 10,000 molesaluminum per mole of metal in said metallocene.
 4. A polymerizationcatalyst system prepared according to the process of claim
 1. 5. Apolymerization catalyst system consisting essentially of a polymer boundmetallocene and an aluminoxane cocatalyst:wherein said polymer boundmetallocene is represented by the formula QM(R)_(m) ZY_(n) ; wherein Qis polystyrene; wherein M is Si, C, Ge, Sn, P, or N; wherein each R is ahydrocarbyl group independently selected from the group consisting ofalkyl and cycloalkyl groups containing 1 to 20 carbon atoms, aryl groupscontaining 6 to 20 carbon atoms, and cyclopentadienyl-type groups, withthe proviso that at least one R group is a cyclopentadienyl-type groupand when M is C at least two R groups are cyclopentadienyl-type groups,wherein said cyclopentadienyl-type groups are cyclopentadienyl,substituted cyclopentadienyl, indenyl, substituted indenyl, fluorenyl,or substituted fluorenyl, wherein the substituents are hydrocarbylgroups containing 1 to 12 carbon atoms, alkoxy groups containing 1 to 12carbon atoms, or halide; wherein m is 2 or 3; wherein Z is Zr, Hf, Ti,or V; wherein each Y is individually selected from the group consistingof halides and cyclopentadienyl-type groups containing 5 to 36 carbonatoms; wherein n is 2 or 3; and wherein said aluminoxane containsrepeating units of the formula ##STR3## wherein each R¹ is a hydrocarbylgroup containing 1-8 carbon atoms, x is 2 to 50.